Process Control

Batch: FA19-CHE Section: B

Group # A
5
Student Name Registration ID
HASSAN JAVED KHOKHAR FA19-CHE-002
BILAL ARIF FA19-CHE-016
SYED ZAMIN KAZMI FA19-CHE-034
AHMAD SOHAIL FA19-CHE-048
IBRAR MAZHAR FA19-CHE-081
MUHAMMAD ZUBAIR FA19-CHE-086

Date Assigned: January 02, 2023

Due Date: January 09, 2023

Instructor:
Dr. Mehwish Batool
 Experiment: LEVEL CONTROLLER UNIT
Objectives:
 Determine the effect of variation in PID characteristics on the response of the level control unit:

 Change in Gain in Proportional (P) Mode

Theory:
P controller is mostly used in first order processes with single energy storage to stabilize the
unstable process. The main usage of the P controller is to decrease the steady state error of the
system. As the proportional gain factor K increases, the steady state error of the system
decreases. However, despite the reduction, P control can never manage to eliminate the steady
state error of the system. As we increase the proportional gain, it provides smaller amplitude and
phase margin, faster dynamics satisfying wider frequency band and larger sensitivity to the noise.
We can use this controller only when our system is tolerable to a constant steady state error. In
addition, it can be easily concluded that applying P controller decreases the rise time and after a
certain value of reduction on the steady state error, increasing K only leads to overshoot of the
system response. P control also causes oscillation if sufficiently aggressive inthe presence of lags
and/or dead time. The more lags (higher order), the more problem it leads. Plus, it directly
amplifies process noise.

P-I controller is mainly used to eliminate the steady state error resulting from P controller.
However, in terms of the speed of the response and overall stability of the system, it has a
negative impact. This controller is mostly used in areas where speed of the system is not
anissue. Since P-I controller has no ability to predict the future errors of the system it cannot
decrease the rise time and eliminate the oscillations. If applied, any amount of I guarantees set
point overshoot.

The aim of using P-D controller is to increase the stability of the system by improving control
since it has an ability to predict the future error of the system response. In order to avoid effects
of the sudden change in the value of the error signal, the derivative is taken from the output
response of the system variable instead of the error signal. Therefore, D mode is designed to be
proportional to the change of the output variable to prevent the sudden changes occurring in the
control output resulting from sudden changes in the error signal. In addition, D directly
amplifiesprocess noise therefore D-only control is not used.
 The actuator is an electric immersion pump (2), which delivers water from a supply tank into
the liquid level tank (3). The pump must be actuated by an external input signal, e.g. from a
controller. The liquid level is recorded using the pressure of the water column in the tank. The
level tank contains an ascending pipe for this purpose. An air hose (4) conveys the pressure
from its upper end to a pressure sensor inside the unit. The liquid level is then provided as an
electric voltage signal. The electrically operated bleeder valve (6) can be used to set the
discharge from the tank by assigning the influencing variable Z. The valve operates
proportionally and can be variably adjusted. Its position can only be influenced by external
control (e.g. via a PC). The exception is a disturbance in the system. The bleeder valve can be
spontaneously switched to Z =100% using the button (11). The overflow (5) prevents water
from escaping if the discharge through the valve
(6) is not enough. The pump signal lamp (9) and the bleeder valve signal lamp(10) indicate whether
the respective elements are actuated.
Diagram:
Apparatus:
 Water Storage Tank

 Water Level Tank

 Pump

 PID system

Experimental Procedure:

1. Fill the water storage tank with water to at least 80% level.

2. Attach the PC to the level control unit and open the software.

3. Select the “Level Control Unit”. A pop-up window is appeared which can be used to
study the parameters of PID controllers.

4. The pump should not be energized/ operated until your control setting is complete and
whenever you are giving new values/changing values of gain or etc. the pump should be
switched off.

5. Set the controller to “Continuous Mode” on the PC.

6. “W” represents the reference variable / set point. “X” represents the measured variable /
level of liquid in the upper tank, “Z” represents the %age opening of drain valve of
upper tank and “Y” represents the controlled variable.

7. Give set point a value of 50%, and disturbance variable a value of 40%.

8. Vary the values of proportional gain from 20 to 100 and check the response of the
system. Make sure that values of reset time and rate time are zero. This will be a P
arrangement. Compare the system on all values of gain and report the optimum
operational condition.
 9. Now, at a certain value of gain, vary the value of reset time from 10 to 50 s. Make sure
that value of rate time is zero. This will be PI arrangement. Compare the system and
report the optimum operational condition.

10. Take the screenshots of the generated graphs at an interval of 1 minutes.

Safety Observations:
1. Don’t rum pump idle.
2. Ensure that at the end of the experimental performance, the pump should be stopped.
3. Make sure that no water splashes on the floor, as it may lead to the tripping hazard.
4. Wear Lab Coat and Safety Goggle while performing the experiment.

5. Make sure tap water used is free from any contamination to prevent blockage inside the
condenser.
Observations and Calculations:
Time (s) response of Experimental Time Experimental Response
system
0 0 59.09903 0.068
4 0.725076988 62.00353 0.34369
6 1.036727117 66.43949 0.63907
8 1.318719816 69.39679 0.85113
10 1.573877361 73.04062 1.10409
14 2.013658785 75.99793 1.29495
17 2.290340272 79.69456 1.4646
19 2.453035906 84.13052 1.61153
20 2.528482235 88.51367 1.71757
25 2.853980813 94.42829 1.90842
28 3.013612144 101.02942 2.03566
39 3.430903714 107.63055 2.11897
45 3.578403102 113.54516 2.18259
50 3.671660006 123.84293 2.26742

Findings:
Increasing the time constant, the response of system becomes slow and system reaches the
reference height by taking large time.
 Display Results:

 Take the screenshots of graphs generated online at an interval of 1 minute and compare
all the cases.

Conclusion:
Response is 1st order with respect to input change because model used in above calculation is 1st
order in nature. Hence the response is theoretically perfect.
Increasing the time constant, the response of system become slow and system reaches the
reference height by taking large time.
 When time constant is small.
 When time constant is large